PROJECT

ON
LOW OIL PRESSURE PROBLEM FOUND AT
ENGINE OF MAHINDRA JEETO.

MAHINDRA & MAHINDRA Ltd.

ZAHEERABAD PLANT.

Training Details

NAME: ARPAN DEB MONDAL & ANINDYA SEKHAR DAS..

YEAR:: 2015.
ORGANIZATION:: MAHINDRA
MAHINDRA &
& MAHINDRA
MAHINDRA Ltd.
Ltd. ZAHEERABAD
ZAHEERABAD
PLANT.
PLANT.

PLACE
PLACE OF
OF TRAINING:
TRAINING: ZAHEERABAD,
ZAHEERABAD,
(HYDERABAD).

DESIGNATION OF GUIDE::
PILLAI

PERIOD::
DURATION::

Mr.
Mr. K.
K. SATYA
SATYA SAI
SAI &
& Mr.
Mr. RAJESH
RAJESH

(Dept.m_DURA ENGINE SHOP)

FROM
FROM 22
22 OF
OF JUNE
JUNE 2015
2015 TO
TO 21
21 OF
OF JULY
JULY 2015
2015..
2929- DAYS
DAYS..

FIELD OF TRAINING:

P801
P801 ENGINE
ENGINE SHOP
SHOP

Acknowledgement
Gratitude is the hardest emotion to express and often one does not find
adequate words to convey ones entire feeling. We express our sincere
gratitude and deep indebtedness to the H.R. management for granting us the
permission as a summer trainee. we own our gratitude to Mahindra &
Mahindra ltd. Zaheerabad for providing us the opportunity to undergo project
and allowing us to gained vast knowledge about the industry and the other
aspects of the organization during our training period. it is our foremost duty
to express our deep sense of gratitude and respect to Mr. K. Satya Sai
(m_DURA Engine Shop) for his valuable guidance as well as uplifting
tendency and inspiring us for taking up training and completing it
successfully. We greatly appreciate his motivation and understanding
extended for this project work and very thankful to him for his
encouragement and instructions otherwise it could not have been possible
for us. We are also very thankful to each and every staff of Mahindra &
Mahindra who gave their supports in their own ways. As we know well that no

INTRODUCTION OF COMPONY
Group Overview

Mahindra
Mahindra embarked
embarked on
on its
its journey
journey in
in 1945
1945 by
by assembling
assembling the
the Willys
Willys Jeep
Jeep
in
in India
India and
and is
is now
now a
a US
US $17.1
$17.1 billion
billion Indian
Indian multinational.
multinational. It
It employs
employs over
over
7,00,000
7,00,000 people
people across
across the
the globe
globe and
and enjoys
enjoys a
a leadership
leadership position
position in
in
utility
utility vehicles,
vehicles, tractors
tractors and
and information
information technology,
technology, with
with a
a significant
significant and
and
growing
growing presence
presence in
in financial
financial services,
services, tourism,
tourism, infrastructure
infrastructure
development,
development, trade
trade and
and logistics.
logistics. The
The Mahindra
Mahindra Group
Group today
today is
is an
an
embodiment
embodiment of
of global
global excellence
excellence and
and enjoys
enjoys a
a strong
strong corporate
corporate brand
brand
image.
image.

Mahindra
Mahindra is
is the
the only
only Indian
Indian company
company among
among the
the top
top tractor
tractor brands
brands in
in the
the
world.
world. It
It is
is today
today a
a full-range
full-range player
player with
with a
a presence
presence in
in almost
almost every
every
segment
segment of
of the
the automobile
automobile industry,
industry, from
from two-wheelers
two-wheelers to
to CVs,
CVs, UVs,
UVs, SUVs
SUVs
and
and sedan.
sedan. Mahindra
Mahindra recently
recently acquired
acquired a
a majority
majority stake
stake in
in REVA
REVA Electric
Electric
Car
Car Co
Co Ltd.
Ltd. (now
(now called
called Mahindra
Mahindra REVA),
REVA), strengthening
strengthening its
its position
position in
in the
the
Electric
Electric Vehicles
Vehicles domain.
domain.

DEPARTMENTS OF THE
COMPANY
There
There are
are many
many :departments
departments in
in the
the company
company described
described below:
below:
1
1.. CQA
CQA (Central
(Central Quality
Quality Assurance)
Assurance) Dept.
Dept.
2.
2. R&D
R&D (Research
(Research &
& Development)
Development) Dept.
Dept.
3.
3. Logistics
Logistics Dept.
Dept.
4.
4. Production
Production Dept.
Dept.
5.
5. ITS
ITS Dept.
Dept.
6.
6. PD&C
PD&C (Product
(Product Development
Development &
& Control)
Control) Dept.
Dept.
7.
7. Maintenance
Maintenance Dept.
Dept.
8.
8. SQA
SQA Dept.
Dept.

A BREIF INTRODUCTION::
Mahindra
Mahindra ZAHEERABAD
ZAHEERABAD Plant
Plant is
is actually
actually an
an assembly
assembly line
line plant
plant normally
normally
involved
involved in
in the
the production
production of:
of:
1.
1. Bolero
Bolero Champer
Champer
2.
2. Bolero
Bolero Ambulance
Ambulance
3.
3. Alfa
Alfa
4.
4. Jeeto
Jeeto
5.
5. Load
Load king
king
Production
Production of
of Jeeto
Jeeto involves
involves assembling
assembling of
of parts
parts at
at 4
4 different
different levels
levels or
or lines:
lines:
6.
6. Trim
Trim Line
Line
2.
2. Chassis
Chassis Line
Line
3.
3. Engine
Engine Line
Line
4.
4. Main
Main Line
Line

Trim Line

Trim
Trim line
line involves
involves the
the body
body and
and its
its various
various fitments.
fitments.

Major Steps::
1.
1. Removal
Removal of
of Facia.
Facia.
2.
2. Fitment
Fitment of
of Belt,
Belt, Firewall,
Firewall, PU
PU foam,
foam, Roof
Roof Sealer
Sealer (if
(if absent),
absent), Roof
Roof Covering,
Covering,
etc.
etc.
3.
3. Accelerator
Accelerator cable,
cable, Speedo
Speedo Cable,
Cable, Bonnet
Bonnet Cable,
Cable, Clutch
Clutch Beading
Beading fitment.
fitment.
4.
4. Brake
Brake Booster;
Booster; Accelerator,
Accelerator, Clutch
Clutch and
and Brake
Brake Pedal
Pedal fitment.
fitment.
5.
5. Combination
Combination Lamp,
Lamp, Instrument
Instrument Cluster,
Cluster, Battery
Battery fitment.
fitment.
6.
6. Lock
Lock and
and Windscreen
Windscreen Fitment.
Fitment.
7.
7. Blower
Blower Fitment
Fitment and
and various
various Harness
Harness wire
wire fittings.
fittings.

Chassis Line

Engine Line

1.
1. Chassis
Chassis inversion
inversion and
and Rear
Rear axle
axle

1.
1. Pressure
Pressure plate
plate and
and Clutch
Clutch plate
plate

fitment
fitment

mounting
mounting on
on Engine
Engine

2.
2. Suspension
Suspension Fitment
Fitment involving
involving leaf
leaf

2.
2. Assembling
Assembling Transmission
Transmission and
and

spring
spring and
and rear
rear shock
shock absorber
absorber and
and

Engine
Engine and
and mounting
mounting belt
belt

upper
upper and
and lower
lower suspension
suspension arms
arms

connecting
connecting Engine
Engine and
and power
power

along
along with
with springs
springs and
and shock
shock

steering.
steering.

absorbers
absorbers

3.
3. Power
Power Steering
Steering oil
oil tank
tank and
and

3.
3. Pressure
Pressure Application
Application for
for joining
joining

Brake
Brake booster
booster hose
hose pipe
pipe fitment
fitment

upper
upper and
and lower
lower suspension
suspension arms
arms

4.
4. Engine
Engine harness
harness fitment
fitment and
and

4.
4. Filling
Filling differential
differential oil
oil and
and GB
GB valve
valve

some
some of
of its
its connections
connections like
like ground
ground

fitment
fitment

connections,
connections, connections
connections to
to

5.
5. Power
Power steering
steering ,Stead
,Stead wire,
wire,

compressor,
compressor, alternator,
alternator, fuel
fuel

Stabilizing
Stabilizing wire
wire fitment
fitment

injector
injector pump
pump and
and transmission
transmission

Main Line

1.
1. Brake
Brake Beading
Beading fitment(
fitment( including
including handbrake)
handbrake) and
and connections
connections to
to GB
GB valve
valve
and
and front
front and
and rear
rear wheels
wheels
2.
2. Engine
Engine mounting
mounting on
on chassis,
chassis, propeller
propeller shaft
shaft fitment
fitment
3.
3. Body
Body mounting
mounting followed
followed by
by basic
basic connections
connections such
such as
as Brake
Brake Booster
Booster
connections,
connections, Battery
Battery connections,
connections, Power
Power window
window switch
switch connections
connections etc.
etc.
4.
4. Fascia
Fascia preparation
preparation involving
involving Headlight
Headlight fitment,
fitment, coolant
coolant tank
tank fitment
fitment etc.
etc.
5.
5. Radiator
Radiator Fitment
Fitment followed
followed by
by Fascia
Fascia Mounting,
Mounting, Brake
Brake and
and Clutch
Clutch Bleeding
Bleeding
and
and Tire
Tire mounting
mounting
6.
6. Horn
Horn and
and Bonnet
Bonnet Lock
Lock fitment,
fitment, Air
Air filter
filter mount
mount and
and Headlight
Headlight and
and AC
AC pipe
pipe
connections
connections Ac
Ac gas
gas filling
filling ,, Steering
Steering fitment
fitment and
and finally
finally Wiper
Wiper Fitment
Fitment

Shop visit :
Engine Shop :

Assemly Shop :

WORK EXPERIENCE::
We
We worked
worked in
in the
the company
company as
as a
a trainee
trainee in
in ENGINE
ENGINE SHOP
SHOP and
and we
we learnt
learnt many
many
things
things here.
here. The
The experience
experience cannot
cannot be
be described
described in
in words.
words.
The
The experience
experience gained
gained by
by us
us in
in the
the company
company are
are as
as follows.:
follows.:

ENGINE SHOP
It
It is
is place
place where
where the
the whole
whole engine
engine parts
parts are
are machined
machined to
to required
required dimensions
dimensions
and
and assembled
assembled together
together to
to make
make a
a complete
complete engine
engine and
and tested.
tested. And
And a
a basic
basic
inspection
inspection like
like quality
quality and
and metal
metal testing
testing are
are done
done on
on engine
engine part.
part.

Stores
Stores section
section

Machining
Machining section
section (Machine
(Machine shop)
shop)

Engine
Engine assembly
assembly line
line (including
(including sub-assemblies)
sub-assemblies)

Engine
Engine testing
testing

Engine
Engine Rework
Rework room
room

Pre
Pre delivery
delivery inspection
inspection or
or RFI
RFI

RFD
RFD (Ready
(Ready For
For Dispatch)
Dispatch)

ENGINE SHOP LAYOUT

PROCESS FLOW CHART OF ENGINESHOP

Description the department we worked in:

Step-By-step assembly of engine on
assembly line
1. Cylinder head
2. Piston cylinder assembly

assembly

Dowel fixing on upper and lower sides

MOG(Main Oil Gallery)

Lower side dowel are water pump

Steam seals

dowels

Intake and Exhaust valves

Piston rings (oil, middle and

Valve springs

compression)

Valve locking retainers

Cir clip on one side

Piston pin

3. EGR Sub Assembly

Cir clip on 2nd side to lock piston pin

Aligning into piston cylinder

EGR Cooler
EGR Hose

CONTINUATION OF SLIDE
5.Main assembly line
4. Mass balancer and crank

Crank case placing to pallet

shaft assembly

Oil drain nipple to case

Crankshaft oil seal to front and

Align piston crank shaft bearing

back

shields

Wood rough key

Dowel pressing to crank gear

Cylinder unit gasket

Align trigger gear

Cylinder head alignment on

crank case
Align oil filling cap
Hydraulic Lash
adjustment(HLA) placement

CONTINUATION
CONTINUATION OF
OF SLIDE
SLIDE
5. Crank case assembly
Place oil pump dowels
Engine number punching
Alignment of oil pump gear
Oil strainer
Bearing circle
Bearings alignment
Align crank shaft to crank case
Alignment of thrust washer
Crank case MOG (Main Oil gallery)
Mass balancer shaft
Sealant application
Crank case fixing
Oil drain plug & adapter
Alternator bracket
Oil drain nipple
End connector for engine oil check
Hose pipe alignment for oil return
flow
Cylinder studs alignment

Oil drain hose to drain

adapter
Cam cover sealant
Cam lock
Fuel injector
Oil pump and mass balancer
plate
Cooler nut and oil filter
Tappet to cam cover
Speed sensor
Cam oil seal
Fuel distribution pump
Air intake manifold
Banjo pipe
Blow by adapter
Water pump and its adapter
Tensioned pulley (automatic)
Crack sprocket on wood rough
key
Timing belt
Front dust cover
Damper pulley

m-DURA ENGINE
FRONT VIEW

SIDE VIEW

ENGINE BUYOFF
It
It is
is an
an inspection
inspection done
done to
to engine
engine after
after completion
completion of
of assembly
assembly to
to check
check
whether
whether all
all the
the parts
parts are
are correctly
correctly assembled
assembled or
or not.
not. And
And to
to verify
verify if
if any
any
damages
damages occurred
occurred to
to assembled
assembled parts
parts and
and to
to check
check if
if any
any leakages
leakages are
are there
there
from
from aligned
aligned parts.
parts.

Engine Testing
Engine hot testing is performed to inspect the functional parameters of
engine for its performance before delivering it for further assembly in vehicle.
The engine is to be tested to know various parameters like
Oil pressure
Rpm
Torque
Water inlet and outlet temperature
Air intake
Fuel intake pressure and temperature
Exhaust temperature

Rigging Operations
(Outside test bed)
Engine
Engine mounting
mounting bracket
bracket fitment
fitment
Engine
Engine lifting
lifting to
to pallet
pallet
Dowel
Dowel fitment
fitment
Water
Water dummy
dummy adapter
adapter
Water
Water inlet
inlet hose
hose fitment
fitment
Water
Water outlet
outlet hose
hose fitment
fitment
Oil
Oil pressure
pressure QRC
QRC Adapter
Adapter fitment
fitment
Air
Air intake
intake hose
hose dummy
dummy fitment
fitment
Clutch/pressure
Clutch/pressure plate
plate fitment
fitment
Exhaust
Exhaust manifold
manifold fitment
fitment
Engine
Engine test
test bed
bed pallet
pallet bracket
bracket
fitment
fitment
Placing
Placing engine
engine on
on test
test bed
bed pallet
pallet

(Inside test bed)

Test
Test bed
bed movement
movement towards
towards inside
inside
Placing
Placing of
of clutch
clutch shaft
shaft
Water
Water inlet
inlet hose
hose
Water
Water outlet
outlet hose
hose
Fuel
Fuel inlet
inlet fitment
fitment
Fuel
Fuel out
out let
let fitment
fitment
Air
Air intake
intake fitment
fitment
Exhaust
Exhaust manifold
manifold clamp
clamp fitment
fitment
Oil
Oil pressure
pressure QRC
QRC adapter
adapter fitment
fitment
Starter
Starter motor
motor earthling
earthling
Wiring
Wiring harness
harness
Water
Water outlet
outlet temperature
temperature sensors
sensors
Speed
Speed sensor
sensor
Injector
Injector sensor
sensor
FDP
FDP sensor
sensor
Crank
Crank sensor
sensor

Testing
Testing consists 2 cycles
Automatic cycle and FTP (manual cycle)
For testing, engine is made to start and run for certain time period as per
above mentioned cycles in order to get the performance level for mentioned
parameters of an engine.
Oil pressure
Rpm
Torque
Water inlet and outlet temperature
Air intake
Fuel intake pressure and temperature
Exhaust temperature

Engine Re-work :

The engine is rejected at following cases

1. Engine cranking problem
2.
3.
4.
5.

Torque: if below 29Nm

Low oil pressure 1.5bar at 90deg centigrade
Exhaust above 4.5 bar
Oil leakages

TESTING CAPACITY:
450 min/16 min=28 engines.
1test bed = 28 engines/shift
4 test bed = 28*4 engines/shift
=112 engines/shift
For 3 shift the total number of engine
tested=112*2.8

ENGINE OIL CIRCUIT OIL PRESSURE AT DIFFERENT

RPMS & ITS TROUBLESHOOTING

CONCLUSION
What
What did
did II learn?
learn?
Summer training is an integral part of any B-Tech curriculum
in the country. It serves as the only direct exposure to an
organization and its ways of functioning during the entire
curriculum. The summer training in any technology course is
very important for the students and it will help in future
when an student goes to company.
This program is the most effective aid in enabling the students to
relate technical theory to practice, and in making an informed career
choice." Courses are intended to provide a cross-functional
orientation in basic technical concepts, quantitative methods and
analytical skills. Since immediacy of application is not stressed at
this stage, the person can take his own time to reflect on the
subjects and internalize the concepts. Once this conceptual
framework is in place, it needs to be tested under real life
conditions. The technical institutes cannot simulate the real life
conditions of an engineer. Although innovative tools like case
studies do attempt to address these limitations, they fail to capture

THANK YOU